Fluor used innovative approaches to meet the fast-track schedule for the MTBE manufacturing facility:
Pipe Rack Modularization - The pipe rack consisted of precast concrete support bents, structural steel supported pipeways, accessways, and overhead air coolers mounted on top of the entire assembly. The lifting of the pre-dressed column structural steel pipeway portion was fabricated in two sections – in a modularized manner – consisting of accessways, cable trays, and fireproofed structural steel. The piping was also complete with insulation and tracing.
Successful Use of Precast Concrete for Pipe Rack - Precast concrete structures were used to minimize site erection time and interference of crafts associated with fireproofing steel structures. Also, precast ladder structures, with connecting beams and table tops, were used to support plant reactors. Additionally, precast structures were used in place of conventional fireproofed heavy steel structures. The ease of assembly – over approximately 3-1/2 weeks – and the ability to proceed without the need of fireproofing and without inefficiencies due to craft interference, were instrumental in completing construction in this area, which was the last to complete due to licensor design changes. This same approach was used successfully for several minor piperacks with similar benefits.
Dressing of Major Columns at Grade - Pre-dressing of columns prior to erection included installation of piping, cabling, ladders and platforms, and lighting. This was completed for all six of the project's columns and included trays and reboilers for all except the largest tower, which was limited by crane capacity.
This concept was used for cost savings and safety considerations based on the following:
- Maximum height for workers pre-dressing a column was 1.5 column diameters
- Virtually eliminated scaffold requirements
- Executed quicker based on ability of full length of tower available for work and craft workers getting to their jobs quicker than having to make climbs of increasing height as labor progressed
This approach required a great deal of planning and coordination, particularly as this work had to be executed in parallel with design development to be effective.
Shop Fabrication of Small-Bore Piping – Virtually all small-bore piping, down to ½ inch, was pre-fabricated as the accuracy of the 3D CAD system allowed. Significant savings in field installation time and costs were achieved as a result.
3D CAD Design and Construction Planning – Fluor used 3D CAD in the design of the process area, resulting in low levels of rework and allowing approaches such as the shop fabrication of small-bore piping. Use of 3D CAD provided Alberta EnviroFuels the benefits of having the latest design technology without delays in plant completion. The 3D CAD also provided the ability to expeditiously handle the significant licensor changes without having to redesign from scratch.